Batteries, separators, components, and compositions with heavy metal removal capability and related methods

ABSTRACT

In accordance with at least certain embodiments of the present invention, a novel concept of utilizing PIMS minerals as a filler component within a microporous lead-acid battery separator is provided. In accordance with more particular embodiments or examples, the PIMS mineral (preferably fish meal, a bio-mineral) is provided as at least a partial substitution for the silica filler component in a silica filled lead acid battery separator (preferably a polyethylene/silica separator formulation). In accordance with at least selected embodiments, the present invention is directed to new or improved batteries, separators, components, and/or compositions having heavy metal removal capabilities and/or methods of manufacture and/or methods of use thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S.provisional patent application Ser. No. 61/385,259, filed Sep. 22, 2010,to Chambers et al., hereby fully incorporated by reference herein.

FIELD OF THE INVENTION

In accordance with at least selected embodiments, the present inventionis directed to new or improved batteries, separators, components, and/orcompositions having heavy metal removal capabilities and/or methods ofmanufacture and/or methods of use thereof. In accordance with at leastcertain possibly preferred embodiments, the present invention isdirected to new or improved lead acid batteries, lead acid batteryseparators (single or multi-layer), lead acid battery components (suchas battery casings, battery parts, porous bags, laminates, coatings,surfaces, fillers, electrode formulations, electrolytes, and/or thelike) and/or polymer or resin compositions having heavy metal removalcapabilities and/or methods of manufacture and/or methods of usethereof. In accordance with at least possibly more preferred particularembodiments, the present invention is directed to new or improved leadacid batteries, lead acid battery separators (single or multi-layer),lead acid battery components (such as battery casings, battery parts,porous bags, laminates, coatings, surfaces, fillers, electrodeformulations, electrolytes, and/or the like) and/or polymer or resincompositions having heavy metal removal capabilities and utilizing atleast one PIMS mineral as at least one filler component therein. Inaccordance with at least one particular microporous lead-acid batteryseparator embodiment, the PIMS mineral (preferably fish meal, abio-mineral) is provided as at least a partial substitution for thesilica filler component in a silica filled lead acid battery separator(preferably a polyethylene/silica separator formulation). In accordancewith at least certain embodiments or examples, the invention is directedto battery separators, to methods of manufacture of battery separators,to methods of use of battery separators, to improved battery separators,and/or to improved separators or laminates for lead acid batteries.

BACKGROUND OF THE INVENTION

A group of inorganic (mineral) compounds are known to effectively bindheavy metals such as lead, cadmium, iron, zinc, and copper. Themechanism by which the minerals bind heavy metals is termed “PhosphateInduced Metal Stabilization” (PIMS) and is widely utilized for theenvironmental remediation of heavy metals from contaminated soils andwater. In environmental remediation applications, bulk quantities ofminerals possessing PIMS affinty for toxic metals are mixed withcontaminated soil or contained within a housing whereby contaminatedwater may perfuse through the bulk PIMS mineral cake to reduce heavymetal contamination.

A common failure mode within the lead-acid (or lead-calcium) batteryindustry is the phenomenon of “hydration shorts”. This type of shortcircuit is typically formed in batteries when they are allowed to stayat very low acid concentrations (low charge) for an extended period oftime. In a charged state, the acid density is high (for example, 1.28g/cm³) and the solubility of lead sulfate is low. At low charge, theacid density decreases and the solubility of lead sulfate increases. Atlow charge, lead sulfate (PbSO₄), from the electrode plates, enters intothe electrolyte solution (sulfuric acid H₂SO₄). Upon recharging, leadsulfate is precipitated and can form a layer on the bottom of many ofthe separator pores (the separator pores are large compared to the ionicradii of lead and sulfate). Upon additional recharging of the batteryand contact with the negative electrode of the battery, the precipitatedlead sulfate can be reduced to lead and thousands of microshorts betweenthe electrodes can be generated (hydration shorts and battery failure).

Typically, this “hydration shorts” phenomenon occurs when a batteryencounters a slow discharge as in the case of storage over extendedperiods without maintenance of charge. The conventional approach to theprevention of hydration shorts consists of addition of sodium sulfate(Na₂SO₄) to the electrolyte solution during battery manufacture. Thisapproach requires an additional manufacturing step, the addition ofsodium sulfate to the electrolyte, and adds complexity to the batteryprocessing. Sodium sulfate addition acts to “hinder” hydration shortsvia the Common Ion Effect but does not address the root cause (solublelead generation).

As such, there exists a need for new or improved battery separators andthe like for particular battery applications, particular uses, and/orfor addressing, reducing or eliminating the phenomenon of “hydrationshorts” in lead acid batteries.

SUMMARY OF THE INVENTION

In accordance with at least selected embodiments, the present inventionaddresses the need for new or improved battery separators and the likefor particular battery applications, particular uses, and/or foraddressing, reducing or eliminating the phenomenon of “hydration shorts”in lead acid batteries.

In accordance with at least selected embodiments, the present inventionaddresses, provides or is directed to new or improved batteries,separators, components, and/or compositions having heavy metal removalcapabilities and/or methods of manufacture and/or methods of usethereof; new or improved lead acid batteries, lead acid batteryseparators (single or multi-layer), lead acid battery components (suchas battery casings, battery parts, porous bags, laminates, coatings,surfaces, fillers, electrode formulations, electrolytes, and/or thelike) and/or polymer or resin compositions having heavy metal removalcapabilities and/or methods of manufacture and/or methods of usethereof; new or improved lead acid batteries, lead acid batteryseparators (single or multi-layer), lead acid battery components (suchas battery casings, battery parts, porous bags, laminates, coatings,surfaces, fillers, electrode formulations, electrolytes, and/or thelike) and/or polymer or resin compositions having heavy metal removalcapabilities and utilizing at least one PIMS mineral as at least onefiller component therein; a silica filled lead acid battery separatorwherein a PIMS mineral (preferably ground fish meal, a bio-mineral) isprovided as at least a partial substitution for the silica fillercomponent in the silica filled lead acid battery separator (preferably apolyethylene/silica separator formulation); and/or the like.

In accordance with at least selected embodiments, the present inventionaddresses, provides or is directed to new or improved batteries,separators, components (such as battery casings, battery parts, porousbags, laminates, coatings, surfaces, fillers, electrochemically activeelectrode formulations, electrolytes, and/or the like), and/orcompositions having heavy metal removal capabilities utilizing at leastone source of natural or synthetic hydroxyapatite having heavy metalbinding capabilities, such as a PIMS mineral, and/or methods ofmanufacture and/or methods of use thereof.

In accordance with at least selected possibly preferred embodiments ofthe present invention, a believed novel concept of utilizing PIMSminerals as a filler component within a microporous lead-acid batteryseparator is provided. In accordance with one particular possibly morepreferred embodiment or example, the PIMS mineral (preferably fish meal,a bio-mineral) is provided as at least a partial substitution for thesilica filler component in contemporary silica filled lead acid batteryseparator (preferably a polyolefin/silica or polyethylene/silica/oilseparator formulation).

In accordance with selected embodiments or aspects of the presentinvention, a variety of “Phosphate Induced Metal Stabilization” (PIMS)minerals have been identified; some of which have been evaluated forlead affinity. A PIMS mineral derived from fish bone (such ascommercial, lab ground fish meal) has been shown to have greatestaffinity for lead ion over the other samples evaluated. The fish bonepowder was extruded via pilot operation into a typical lead-acid batteryseparator format at several loading concentrations. The resulting PIMSincorporating separator was evaluated for lead removal efficiency; theseparator demonstrated substantial reduction of lead concentration inacidic solution. For example, % Pb reductions of about 17% to 100% weredemonstrated. In accordance with at least certain embodiments, it ispreferred that the fish bone powder be added to substitute for a portionof the silica filler at substitution levels of about 1% to 20% of thesilica, more preferably about 2% to 10%, and most preferably at about 2%to 5%. In accordance with at least other certain embodiments, it ispreferred that the ground fish bone powder (ground fish meal) be addedto substitute for a portion of the silica filler at substitution levelsof about 1% to 50% or more of the silica, more preferably about 5% to30%, and most preferably at about 10% to 20%.

It is believed that this is the first commercial use of a bio-mineral ina battery separator, in an extruded polyolefin polymer resin, and in aporous polymer film or membrane.

In accordance with at least selected embodiments, lead reduction isachieved by incorporating PIMS minerals in lead-acid battery separators,preferably incorporating PIMS mineral derived from fish bone.

The present invention represents a novel or improved microporousmembrane substrate with chemically active properties. A range of variouschemically active or reactive mineral fillers are available and amenableto the separator extrusion and extraction process. These minerals areavailable at low cost in desired purity and in the case of fish bone areindustrial by-products available from multiple sources. Advantagesinclude low cost of raw material as well as streamlining existingbattery production processes involving sodium sulfate.

The preferred separators of the present invention are microporousmaterials (e.g. pores less than 1 micron). Nonetheless, other materialssuch as porous or macroporous materials are contemplated. For example,macroporous separators (e.g. pores greater than 1 micron) would includeseparators made from rubber, PVC, synthetic wood pulp (SWP), glassfibers, cellulosic fibers, polypropylene, and combinations thereof.

In accordance with at least selected embodiments, the present inventionis directed to other components and/or compositions having heavy metalremoval capabilities and/or methods of manufacture and/or methods of usethereof. In accordance with at least certain possibly preferredembodiments, the present invention is directed to new or improved leadacid battery components (such as battery casings, battery parts, porousbags, laminates, coatings, surfaces, fillers, electrodes, electrolytes,and/or the like) and/or polymer or resin compositions having heavy metalremoval capabilities and/or methods of manufacture and/or methods of usethereof. In accordance with at least possibly more preferred particularembodiments, the present invention is directed to such new or improvedlead acid battery components (such as battery casings, battery parts,porous bags, laminates, coatings, surfaces, fillers, electrodes,electrode formulations, electrolytes, and/or the like) and/or polymer orresin compositions utilizing at least one PIMS mineral as at least onefiller component therein. In accordance with at least one particularembodiment, the PIMS mineral (preferably ground fish meal, abio-mineral) is provided as at least a partial substitution for thesilica filler component in a silica filled polymer composition, such asa polyolefin/silica composition, for example, in apolyethylene/silica/oil formulation suitable for slot die extrusion.

In accordance with at least certain other embodiments or examples, theinvention is directed to new or improved batteries, separators,components, and/or compositions having lead removal, binding, bonding,absorbing, retaining, and/or scavenging capabilities and/or methods ofmanufacture and/or methods of use thereof.

In accordance with at least selected objects of the present invention,there is provided new or improved batteries, separators, components,and/or compositions having heavy metal removal capabilities and/ormethods of manufacture and/or methods of use thereof; new or improvedlead acid batteries, lead acid battery separators (single ormulti-layer), lead acid battery components (such as battery casings,battery parts, porous bags, laminates, coatings, surfaces, fillers,electrodes, electrolytes, and/or the like) and/or polymer or resincompositions having heavy metal removal capabilities and/or methods ofmanufacture and/or methods of use thereof; new or improved lead acidbatteries, lead acid battery separators (single or multi-layer), leadacid battery components (such as battery casings, battery parts, porousbags, laminates, coatings, surfaces, fillers, electrodes, electrodeformulations, electrolytes, and/or the like) and/or polymer or resincompositions having heavy metal removal capabilities and utilizing atleast one source of natural and/or synthetic hydroxyapatite having heavymetal binding capabilities, preferably having at least one PIMS mineralas at least one filler component therein; particular microporouslead-acid battery separator embodiments wherein the PIMS mineral(preferably fish meal, a bio-mineral) is provided as at least a partialsubstitution for the silica filler component in a silica filled leadacid battery separator (preferably a polyethylene/silica separatorformulation); battery separators, to methods of manufacture of batteryseparators, to methods of use of battery separators, to improved batteryseparators, and/or to improved separators or laminates for lead acidbatteries; and/or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating at least selected embodiments, featuresand/or aspects of the invention, there is shown in the drawings one ormore forms that may be presently preferred; it being understood,however, that the embodiments, features and/or aspects of the inventionare not limited to the precise arrangements and instrumentalities shown.

FIG. 1 is a schematic perspective view representation of an exemplarylead acid battery, with parts broken away, illustrating a placement ofat least one possibly preferred embodiment of the present separatortherein.

FIG. 2 is a back plan view illustration of an exemplary separator for alead acid battery, with a part folded over.

FIG. 3 is a front plan view illustration of another exemplary separatorfor a lead acid battery, with a part folded over.

FIG. 4 is a front plan view illustration of at least one embodiment ofthe separator of FIG. 1, with a part folded over.

FIG. 5 is a schematic cut-away side elevation view illustration of atleast one embodiment of the separator of the instant invention, with theseparator folded over a positive plate and forming an envelope or pocketabout the plate.

FIG. 5A is an enlarged detail view of a portion of the separator of FIG.5.

FIGS. 6-8 are respective schematic perspective view illustrations ofselected particular embodiments of separators with negative cross ribsof the instant invention.

FIG. 9 is a schematic perspective view illustration of at least aselected embodiment of the manufacture of at least one embodiment of theinventive separator of the present invention.

FIG. 10 is a schematic graphical representation of a fish meal loadingcurve showing the effectiveness of the fish meal in comparison to theloading of the fish meal in % of ground fish meal substituted for silicafiller. The log based curve is based on data in Table II and shows astep increase in effectiveness from about 2% to 20% loading.

DETAILED DESCRIPTION

In accordance with at least selected embodiments, the present inventionis directed to new or improved batteries, separators, components, and/orcompositions having heavy metal removal capabilities and/or methods ofmanufacture and/or methods of use thereof. In accordance with at leastcertain possibly preferred embodiments, the present invention isdirected to new or improved lead acid batteries, lead acid batteryseparators (single or multi-layer), lead acid battery components (suchas battery casings, battery parts, porous bags, laminates, coatings,surfaces, fillers, electrodes, electrode formulations, electrolytes,and/or the like) and/or polymer or resin compositions having heavy metalremoval capabilities and/or methods of manufacture and/or methods of usethereof. In accordance with at least possibly more preferred particularembodiments, the present invention is directed to new or improved leadacid batteries, lead acid battery separators (single or multi-layer),lead acid battery components (such as battery casings, battery parts,porous bags, laminates, coatings, surfaces, fillers, electrodes,electrode formulations, electrolytes, and/or the like) and/or polymer orresin compositions having heavy metal removal capabilities and utilizingat least one source of natural or synthetic hydroxyapatite having heavymetal binding capabilities, preferably at least one PIMS mineral as atleast one filler or component therein or thereon. In accordance with oneparticular microporous lead-acid battery separator embodiment orexample, the PIMS mineral (preferably fish meal, a bio-mineral) isprovided as at least a partial substitution for the silica fillercomponent in a silica filled lead acid battery separator (preferably apolyethylene/silica separator formulation).

In accordance with at least selected embodiments of the presentinvention, a believed novel concept of utilizing “Phosphate InducedMetal Stabilization” (PIMS) minerals as a filler component within amicroporous lead-acid battery separator is provided. In accordance withone particular embodiment or example, the PIMS mineral (preferably fishmeal, a bio-mineral) is provided as at least a partial substitution forthe silica filler component in contemporary silica filled lead acidbattery separator (preferably a polyethylene/silica separatorformulation).

As mentioned above, a common failure mode within the lead-acid batteryindustry is the phenomenon of “hydration shorts”. In accordance with atleast selected embodiments, the present invention is directed to new orimproved batteries, separators, components, and/or compositions havingheavy metal removal capabilities that address, delay, reduce, oreliminate the phenomenon of “hydration shorts”.

In accordance with the present invention, a variety of PIMS mineralshave been identified and some of which have been evaluated for leadaffinity (see Tables I and II below). A PIMS mineral derived from fishbone (such as commercial, lab ground fish meal) has been shown to havethe greatest affinity for lead ion over the other samples evaluated. Thefish bone or fish meal powder was extruded via pilot operation into atypical lead-acid battery separator format at several loadingconcentrations. The resulting PIMS incorporating separator was evaluatedfor lead removal efficiency; the separator demonstrated substantialreduction of lead concentration in acidic solution. For example, % Pbreductions of about 17% to 100% were demonstrated. It is preferred thatthe fish bone powder be added to substitute for the silica filler atsubstitution levels of about 1% to 20% of the silica, more preferablyabout 2% to 10%, and most preferably at about 2% to 5%. In accordancewith at least other certain embodiments, it is preferred that the groundfish bone powder (ground fish meal) be added to substitute for a portionof the silica filler at substitution levels of about 1% to 50% or moreof the silica, more preferably about 5% to 30%, and most preferably atabout 10% to 20%.

It is believed that this is the first commercial use of a bio-mineral ina battery separator, in an extruded polyolefin polymer resin, and in aporous polymer film or membrane.

In accordance with at least selected embodiments, lead reduction isachieved by incorporating PIMS minerals in lead-acid battery separators,preferably incorporating PIMS mineral derived from fish bone.

The present invention represents a novel microporous membrane substratewith chemically active properties. A range of various chemically activeor reactive mineral fillers are available and amenable to the separatorextrusion and extraction process. These minerals are available at lowcost in desired purity and in the case of fish bone (or fish meal) areindustrial by-products available from multiple sources. Advantagesinclude low cost of raw material as well as identified batterymanufacturer need to streamline existing production processes involvingsodium sulfate.

The preferred separators are microporous materials (e.g. porous lessthan 1 micron). Nonetheless, other materials such as porous ormacroporous materials are contemplated. For example, macroporousseparators (e.g. pores greater than 1 micron) would include separatorsmade from rubber, PVC, synthetic wood pulp (SWP), glass fibers,cellulosic fibers, polypropylene, and combinations thereof.

In accordance with at least selected embodiments, the battery may be alead acid or lead calcium battery such as a vented or flooded lead acidbattery, enhanced flooded lead acid battery (EFB), valve-regulatedlead-acid (VRLA) battery, low-maintenance lead-acid rechargeablebattery, absorbed glass mat (AGM) battery, VRLA AGM battery, gel battery(gel cell), VRLA gel battery, sealed lead-acid battery, recombinantbattery, polymer battery, carbon lead acid battery, or other battery,capacitor, super capacitor, accumulator, battery/capacitor combination,and/or the like. The preferred battery is a vented or flooded lead acidbattery.

In accordance with at least selected embodiments, the battery separatormay be a lead acid or lead calcium battery separator, such as a flexibleor rigid separator, a pocket, envelope, sheet, piece or leaf separator,a single or multi-layer separator, a composite or laminate separator, aseparator for a vented or flooded lead acid battery, enhanced floodedlead acid battery (EFB), valve-regulated lead-acid (VRLA) battery,low-maintenance lead-acid rechargeable battery, absorbed glass mat (AGM)battery, VRLA AGM battery, gel battery (gel cell), VRLA gel battery,sealed lead-acid battery, recombinant battery, polymer battery, carbonlead acid battery, or other battery, capacitor, super capacitor,accumulator, battery/capacitor combination, and/or the like. Thepreferred battery separator is a vented or flooded lead acid batteryseparator.

Hydroxyapatite is a mineral with demonstrated heavy metal bindingcapabilities. Hydroxyapatite can be produced synthetically and purifiedas a nano-crystalline material. Hydroxyapatite is found within theskeletal mass of many naturally occurring plants and animals (as well asa minor constituent of naturally occurring minerals such as kaolinite).The most common animal-derived sources of hydroxyapatite are aquatic(fish, crustaceans, shellfish) and land-based from bovine and porcinesources. The most common plant-derived sources of hydroxyapatite occurin tea, kelp and various species of tree bark. As with all naturalproducts, varying degrees of purity and potency may be expected. As anexample, fish meal is commercially available in a range of puritiesbased upon the level of digestion of non-skeletal remains. That is, fishmeal may contain high amounts of protein from fleshy components thatremain; this may be termed “high-nitrogen” fish meal. Fish meal that hasbeen fully processed to fully digest proteinaceous matter, leavingskeletal content intact may be termed “high-phosphorus” fish meal.

Most animal and plant derived sources of hydroxyapatite are commerciallysupplied as coarse granular materials. In accordance with at least oneembodiment, aspect or example of the present invention, in order toefficiently make use of the hydroxyapatite-bearing materials it isdesirable to perform a milling (or grinding) operation to reduce theparticle size and increase the effective surface area in an effort topromote optimal exposure of the heavy metal to the hydroxyapatite. Themilling operation also promotes ease of particle incorporation into thebattery by, for example, membrane extrusion, impregnating, coating,laminating, molding, sachet fabrication, or combinations of thesetechnologies. It is preferred, for example, to achieve a D50 particlesize of between 10 μm to 80 μm to achieve optimal condition for theincorporation of ground fish meal into a battery separator via twinscrew extrusion methodology. The aforementioned particle size range isalso desirable when incorporating natural hydroxyapatite materials intonon-woven laminate-separator structures, impregnating, coating, molding,and bulk powder sachet-type delivery methods.

In accordance with at least selected embodiments of the presentinvention, it is preferred to compound the hydroxyapatite source (i.e.ground or milled fish meal) into the separator extrusion formulation(such as a polymer/silica/fish meal formulation or a polymer/silica/fishmeal/oil formulation). Separators produced in this way offer the desiredelectrochemical performance attributes of known lead acid batteryseparators but surprisingly surpass the conventional separatorcapabilities by actively sequestering lead in solution. In deepdischarge condition, the electrolyte contains an elevated level ofreduced lead passing through the tortuous separator matrix and inaccordance with at least selected embodiments of the present inventionthe separator comprises extrusion immobilized hydroxyapatite (fish meal)to sequester elemental lead prior to migration to the negativeelectrode. Therefore, in accordance with at least selected possiblypreferred embodiments, sources of hydroxyapatite are preferablyimmobilized by incorporation into the separator extrusion process toexploit surface area contact probability and proximity to the electroderequiring protection.

Another approach to the incorporation of hydroxyapatite into theseparator and/or battery is the inclusion of the reactive mineral into alaminate mat which is adjacent to the separator and/or attached to theseparator by attachment means such as welding, spot welding, ultrasonicwelding, adhesive, heat, heat and pressure, or other known processes.The laminate may be a glass mat and the fish meal or other source ofhydroxyapatite may be mixed with a binder utilized during formation ofthe glass mat, coated on the mat, and/or impregnated in the mat. Thefish meal or other source of hydroxyapatite may be co-extruded with theresin during the fiberization process thus allowing for inclusion into“carded” dry process non-wovens as well as wet-laid processes.Alternatively, the fish meal or other source of hydroxyapatite may alsobe used within synthetic non-woven materials, such as PBT, PET, PP,and/or the like by means of addition to the binder and/or by directaddition to the furnish prior to wet-lay fiber formation. This methodalso has utility in adding fish meal or other source of hydroxyapatiteto cellulosic laminates such as “pasting papers”. One or more sources ofhydroxyapatite may also be incorporated on or in the separator by meansof, for example, coated adhesion (after separator formation), directinclusion (during formation), to both inorganic and organic fibrouslaminate materials in contact with the separator, and/or combinationsthereof.

Another approach to the incorporation of hydroxyapatite (such as groundfish meal) is to coat the fish meal directly to the positive and/ornegative surface of the separator. An example of this method is toproduce a slurry of the desired concentration, coat the positive ornegative surface with the slurry by known coating means (dip, spray,roller, nip, etc.) and subsequently dry the slurry-separator article toinsure immobilization of the fish meal during any prerequisite separatorprocessing steps prior to the battery build and formation. Therefore,sources of hydroxyapatite can be applied by mixing with a vehicle, forexample water (or other solvent or binder), to produce a slurry ormixture suitable for the application of a surface coating (preferably aporous coating).

Another approach to the incorporation of hydroxyapatite into the energystorage device is by compounding the reactive mineral, (e.g. fish meal),into the resin utilized in producing the container hardware for thebattery itself (the case, supports, dividers, cover, and/or the like).Thus, some level of contact over time may occur with electrolytesolution and the surface of the resin case, supports, dividers, topcover and associated parts comprising the battery compartment.Additionally, parts comprising the battery compartment may be injectionmolded in such a way as to incorporate active material (the reactivemineral) such as fish meal into the inner or interior surfaces thereofat relatively elevated concentrations; this is generally referred to as“in-molding”. Further, sachet devices whereby the hydroxyapatite iscontained as a bulk powder within a porous, non-woven, paper, and/orplastic enclosure or another design allowing for the storage ofhydroxyapatite in free electrolyte solution can be utilized to rapidlyor over time release the active agent (reactive mineral) into theelectrolyte (such as fish meal impregnated glass fiber, glass mat orother non-woven packing material, time release beads, a gel containingthe reactive mineral, etc.). The direct inclusion of the hydroxyapatitein the electrolyte bulk storage may be utilized to provide a fixed doseof the ingredient during electrolyte filling immediately prior tobattery formation or at any time during the battery manufacturingprocess. It is also possible to mix the hydroxyapatite (such as fishmeal) into the electrochemically active material coating which isapplied to the positive and negative electrodes respectively. Theprocess of preparing the active material chemistries and the process ofapplying the active material to the electrode grids may be modified toinclude the addition of fish meal or other hydroxyapatite material (thereactive mineral may be included in the electrochemically activeelectrode formulations). Finally, hydroxyapatite may also have utilityas an additive later in the life of the battery, for example, after asuggested service interval the battery is injected with a level ofhydroxyapatite to increase service life through continued protectionagainst depolarization of the negative electrode (and prevention of“hydration shorts”).

In accordance with selected examples and testing of hydroxyapatitematerials, the following Table I illustrates the unexpected resultsachievable with even low loading of hydroxyapatite (such as fish meal).For example, a 10% loading of fish meal as a substitution for silicafiller in the battery separator of Sample G showed an amazing 72.6%reduction in lead in the 20 ml Pb solution.

TABLE I Sample Composition weight (g) solution (ml) Pb (mg/L) % Change APb Standard Solution As received (~100 ppm from vendor) N/A 20 114Control B Hydroxyapatite mineral powder (Aldrich Reagent grade) 0.7 200.614 99.5 C Calcium Phosphate tribasic powder (Aldrich) 0.7 20 0.4399.6 D Fish Meal (Commercial, lab ground) 0.7 20 0.002 100.0 EPolyethylene separator w/Si:PE ratio of 2.6:1 (CONTROL) 1.0 20 91.3 19.9F Polyethylene separator as “E”, above w/5% fish meal substituted forsilica. 1.0 20 94.6 17.0 G Polyethylene as “E”, above but w/10% fishmeal substituted for silica. 1.0 20 31.2 72.6 Notes: All samples weresoaked without agitation in the Pb standard solution for 4 days prior toanalysis at testing service. The Pb standard solution (FisherScientific) is comprised of ~100 ppm (mg/L) Pb in a solution of Nitricacid and water. pH = 1-2 All solution samples were filtered free ofparticulate attesting service prior to testing.The Sample E control separator (silica filled) showed a 19.9% reductionin Pb. However, the control separator data is subject to the reversibleadsorptive removal mechanism of precipitated silica. As silica contentis substituted for by the hydroxyapatite source (Sample F), theadsorptive mechanism is gradually disrupted and eventually replaced bythe PIMS sequestration binding mechanism (Sample G). In other words, thereductions in Pb in Samples F and G are permanent binding(sequestration) as compared to temporary adsorption by Sample E.The Sample B, C and D powdered (neat) samples were readily wet-out andimmersed within the Pb assay solution; complete contact of powder tosolution was observed.The Sample E, F and G separator membrane samples were treated with acommercially available surfactant at levels comparable to that utilizedfor typical lead-acid battery separators.All separator membrane samples readily wet-out and immersed within thePb assay solution; complete contact to the surface and underlying poreswas observed.

In accordance with other selected examples and testing of hydroxyapatitematerials, the following Table II (and the curve of FIG. 10) illustratesthe surprising results achievable with even low loading ofhydroxyapatite filler (such as fish meal). For example, a 10% loading offish meal as a substitution for silica filler in the battery separatorof Sample L showed an unexpected 56.2% reduction in lead in the 20 ml Pbsolution, while a 50% loading of fish meal as a substitution for silicafiller in the battery separator of Sample M showed an amazing 99.6%reduction (substantially complete elimination) in lead in the 20 ml Pbsolution. The Pb reduction results of Samples J to M are the data pointsin FIG. 10.

TABLE II Pb Reduction Pb Concentration in Control Pb Concentration PostPb Post Sample Weight Standard Theoretical Exposure Exposure ID ActualID (g) (ml) (ppm) (ppm) (%) A Control Pb N/A 20 100 95.4 N/A StandardControl B Hydroxyapatite 0.11 20 100 0.7 99.3% Synthetic Mineral CCommercial 0.11 20 100 0.1 99.9% Fish Meal Powder (High PhosphorousType) D Commercial 0.11 20 100 82.1 13.9% Beef Bone Meal Powder EControl 1.6 20 100 80.7 15.4% Separator I (CSI) F 2% Beef Meal 1.6 20100 90.9 4.7% (CSI) G 5% Beef Meal 1.6 20 100 84.9 11.0% (CSI) H 10%Beef Meal 1.6 20 100 82.5 13.5% (CSI) I Control 1.6 20 100 72.6 23.9%Separator II (CSII) J 2% Fish Meal 1.6 20 100 89.1 6.6% (CSII) K 5% FishMeal 1.6 20 100 78.9 17.3% (CSII) L 10% Fish Meal 1.6 20 100 41.8 56.2%(CSII) M 50% Fish Meal 1.6 20 100 0.3 99.6% (CSII) N Commercial 0.11 20100 80.5 15.6% Loose Tea LeavesThe Samples E and I control separators (silica filled ˜70%) showedrespective 15.4% and 23.9% reductions in Pb. However, the controlseparator data is subject to the reversible adsorptive removal mechanismof precipitated silica. As silica content is substituted for by the fishmeal hydroxyapatite source (Samples J and K), the adsorptive mechanismis gradually disrupted and eventually replaced by the PIMS sequestrationbinding mechanism (Samples L and M). In other words, the reductions inPb in Samples L and M are permanent binding (sequestration) as comparedto temporary adsorption by Samples E and I.The Samples B, C, D and N powdered (neat) samples were readily wet-outand immersed within the Pb assay solution; complete contact of powder tosolution was observed.The Samples E to M separator membrane samples were treated with acommercially available surfactant at levels comparable to that utilizedfor typical lead-acid battery separators.All separator membrane samples readily wet-out and immersed within thePb assay solution; complete contact to the surface and underlying poreswas observed.The Pb assay test method was carried out via ICP/MS EPA Method 200.8All samples were static soaked without agitation for a period of 48-72hours.The phosphorus level of all samples Post Exposure was tested and foundto be below max acceptable levels.

A group of inorganic (mineral) compounds are known to effectively bindheavy metals such as lead, cadmium, iron, zinc and copper. The mechanismby which the minerals bind heavy metals is termed “Phosphate InducedMetal Stabilization” (PIMS) and is widely utilized for the environmentalremediation of contaminated soils and water. In environmentalapplication, bulk quantities of minerals possessing PIMS affinity fortoxic metals are mixed with contaminated soil or contained within ahousing whereby water may perfuse through the bulk mineral cake.

In accordance with certain improved environmental remediationembodiments of the present invention, we propose the novel concept ofadding at least one source of hydroxyapatite (HA) or hydroxylapatite(such as synthetic and/or natural hydroxyapatite, preferably PIMSminerals, more preferably ground fish bone or meal) to a high surfacearea polymer structure, preferably a porous polymer membrane, morepreferably a microporous polyolefin membrane (flat sheet or hollowfiber), most preferably a microporous polyethylene membrane utilizingPIMS minerals as a filler, preferably as a partial substitution for thesilica filler component of a silica filled microporous polyethylenemembrane. The hydroxyapatite mineral filled membrane can be used as afilter medium, packing, liner, or the like to facilitate removal ofheavy metals from contaminated liquids such as water.

In accordance with at least selected embodiments of the presentinvention, new or improved batteries, separators, components, and/orcompositions have heavy metal removal capabilities via chemically activeproperties provided by one or more chemically active or reactive,natural or synthetic, mineral fillers, particles, coatings, agents, andthe like, preferably bio-minerals from bone or teeth, more preferablyfish bone or meal. Such new or improved batteries, separators,components, and/or compositions have advantages of low cost of rawmaterial, lead removal, reducing the need for sodium sulfate, extendingbattery warranty, use of recycled or industrial waste or by products,and/or the like.

In accordance with at least selected embodiments of the presentinvention, we have:

-   -   Incorporated a material compatible with current separator        production processes into battery separators to systematically        bind Pb in solution and reduce the occurrence of hydration        shorts over the battery service life.    -   Incorporated a material from common (and renewable) sources:        -   Fish (Most efficient at low to very low pH)            -   Bones            -   Scales        -   Crustaceans (Functional range similar to fishmeal)            -   Exoskeleton        -   Shellfish (Most efficient in basic conditions above pH 8.5)            -   Shell        -   Beef (Functional range similar to fish meal)            -   Bones        -   Peat (Functional range near neutral pH)            -   Humus, decayed vegetative matter.        -   Tea Waste (Functional range near neutral pH)            -   By-products of tea manufacturing, stems, undesired                leaves.    -   Identified possibly preferred fish meal as from “pelagic” fish        species.        -   Small, bony fish often considered inedible by humans.        -   Shellfish may also make up a minor component.        -   Fish meal is essentially the bone and scale after            purification, wash, dry and grinding.            -   Typically between 4 and 6% residual oil remains with the                fishmeal.            -   The fishmeal is comprised of the mineral Apatite                w/formula:            -   Ca_(10-x)Na_(x)(PO₄)_(6-x)(CO₃)_(x)(OH)₂

In accordance with at least selected possibly preferred embodiments, thepresent invention is directed to battery separators having one or morePIMS minerals as a filler component, battery separators having one ormore fish bone or fish meal fillers, polyethylene and silica batteryseparators having fish bone powder substituted for at least a portion ofthe silica filler, and/or methods of manufacture or use thereof.

With reference to FIGS. 1 to 9 of the drawings, non-limiting embodimentsor examples of a battery, battery separators, and a separator productionprocess are shown. The inventive embodiments or aspects of the presentinvention are not limited to the particular battery, separators, orproduction process shown in the drawings.

Referring to the drawings wherein like elements have like referencenumerals, there is shown in FIG. 1 an illustration of an exemplary leadacid battery 10, for example, a flooded lead acid SLI battery. Battery10 includes a negative plate (electrode) 12 and a positive plate(electrode) 16 with an exemplary possibly preferred separator 14sandwiched there between. These components are housed within a container18 that also includes terminal posts 20, vents 22, and gang-vent plugs24. The separator 14 has transverse ribs 52 on the surface 54 that facesnegative plate 12 and has longitudinal ribs 56 on the surface 58 thatfaces positive plate 16 (see, for example, FIGS. 1, 4 and 5). Although aparticular battery is shown, the inventive separator may be used in manydifferent types of batteries or devices including for example, but notlimited to, sealed lead acid, flooded lead acid, ISS lead acid, combinedbattery and capacitor units, other battery types, capacitors,accumulators, and/or the like.

The possibly preferred separator 14, of FIGS. 1, 4 and 5, is preferablya porous polymer membrane (such as a microporous polyethylene membranehaving pores less than about 1 micron). Nevertheless, the inventiveseparators may be microporous or macroporous membranes (having poresgreater than about 1 micron) made of natural or synthetic materials,such as polyolefin, polyethylene, polypropylene, phenolic resin, PVC,rubber, synthetic wood pulp (SWP), glass fibers, cellulosic fibers, orcombinations thereof, more preferably a microporous membrane made fromthermoplastic polymers. The possibly preferred microporous membranes mayhave pore diameters of about 0.1 micron (100 nanometers) and porositiesof about 60%. The thermoplastic polymers may, in principle, include allacid-resistant thermoplastic materials suitable for use in lead acidbatteries. The preferred thermoplastic polymers include polyvinyls andpolyolefins. The polyvinyls include, for example, polyvinyl chloride(PVC). The polyolefins include, for example, polyethylene, ultrahighmolecular weight polyethylene (UHMWPE), and polypropylene. One preferredembodiment may include a mixture of filler (for example, silica and/orreactive mineral) and UHMWPE. In general, the preferred separatorprecursor may be made by mixing, in an extruder, about 30% by weightfiller with about 10% by weight UHMWPE, and about 60% processing oil.The mixture may also include minor amounts of other additives or agentsas is common in the separator arts (such as wetting agents, colorants,antistatic additives, and/or the like) and is extruded into the shape ofa flat sheet. The ribs are preferably formed by the engraved surfaces ofopposed calender rollers (see FIG. 9). Thereafter, much of theprocessing oil is extracted, and the microporous membrane is formed.

Separator 14 preferably includes a backweb 59, a positive electrode side58 and a negative electrode side 54. The positive electrode side or face58 preferably includes a plurality of longitudinally extending majorribs 56. Major ribs 56 may be any pattern including for example, seeFIG. 4, spaced longitudinal ribs on one face of the separator. Also, asis known in separators, in the areas to be folded over and sealed orjoined, the ribs 56 may be shorter or eliminated to provide for a goodseal or weld.

The negative electrode side or face 54 (technical back) preferablyincludes a plurality of transversely extending ribs 52 (negative crossribs), see FIG. 4, the part folded over, or FIGS. 1, 5 and 5A. Ingeneral, transversely extending ribs 52 include any substantiallytransverse or non-longitudinal rib pattern (such rib patterns wouldapparently block or impede the escape of gases formed at the negativeelectrode during charging (or over charging)). Non-limiting examples ofthese rib patterns include: continuous (i.e., side-to-side) linear ribs52 of side 54 of separator 14, FIGS. 1, 4, and 5; cross-hatched(diagonal, diamond or knurled); sinusoidal or wavy continuous; wavydiscontinuous; or intermittent and registered linear. Other rib patternswhich include variations of the foregoing are also included.

With reference again to FIGS. 1, 5 and 5A of the drawings, the separator14 may be folded over the positive plate or electrode 16 with positiveribs 56 contacting plate 16 and negative ribs 52 facing outwardly towarda negative plate 12 (to form a pocket or envelope). In accordance withone particular example, cross ribs 52 are about 4 mils thick, backweb 59is about 6 mils thick and positive ribs 56 are about 20 mils thick(total separator thickness about 30 mils).

With reference to FIGS. 1 and 5, the preferred separator 14 may be a cutpiece separator or a wrapping, envelope, pouch, pocket, or laminate withglassmat or synthetic non-woven type separator, and have minortransverse cross-ribs on the opposite face of the separator as the majorlongitudinal ribs.

The transverse cross-ribs on the opposite face of the separator as thelongitudinal ribs increase stiffness and protection of the sheetallowing for reduction of mass of the back-web, reduced ER, reducedcost, and increased physical properties such as may be required for highspeed production and assembly (including high speed separator, envelope,and/or battery production and/or assembly). Such separators orprecursors can be produced in rolls, envelopes (or pockets) and pieces,and may be used where processing of separators by high speed automationor hand assembly is utilized and high productivity is desired.

Also, the mass of the separator can be reduced while maintainingphysical properties needed for processing and performance inside thebattery by adding transverse or cross ribs opposite, for example, themajor longitudinal ribs. The mass of the major rib is preferably reducedwhen the cross ribs are added to the opposite side to achieve thedesired overall separator thickness (major rib+backweb+cross rib). Thesheet can also be reduced in thickness and/or mass while maintainingproductivity properties such as rigidity as well as protecting the sheetfrom abrasion and oxidation rips and tears during the life of thebattery by adding transverse or cross ribs.

In accordance with at least one example or embodiment, small, tightlyspaced transverse ribs are added to the side of the lead acid separatorwhich contacts the negative electrode (preferably in addition to majorribs on the positive side). The small, tightly spaced negativetransverse ribs can be in many different forms, as seen for example inFIGS. 6 to 8, including without limitation, sinusoidal, diagonal orstraight rib patterns, that are continuous or discontinuous. For ease ofprocessing, the rounded straight ribs of FIGS. 5 and 6 to 8 may bepreferred.

The positive longitudinal major ribs can take many forms that runsubstantially in the longitudinal directional, for example, sinusoidal,diagonal or straight ribs, that are continuous or discontinuous. Forease of processing, the rounded straight ribs of FIGS. 6 to 8 may bepreferred. In certain battery designs, often referred as the JapaneseDesign, there are no positive ribs, instead they are replaced with aheavy glass-mat laminated to the flat positive face of the separator. Inthis glass-mat positive face separator embodiment, the transversenegative ribs of the present invention function in the same fashion asthe embodiments with positive longitudinal ribs. The positive face maybe smooth or flat, have projections, have ribs, or have a nonwovenbonded or laminated thereto. Such nonwoven materials may be formed ofsynthetic, natural, organic or inorganic materials or blends, such asfiberglass, polyester (PET), recycled PET, or combinations thereof (withor without the inventive reactive minerals). The separator may be a cutpiece separator or a wrap, envelope, pouch, or pocket type separator.

With regard to at least selected particular embodiments or examples ofseparators, separator 14 preferably has the following:

-   1) Transverse Rib Height—preferably between about 0.02 to 0.30 mm,    and most preferably between about 0.075 to 0.15 mm.-   2) Sheet (Substrate) Thickness—preferably between about 0.065 to    0.75 mm.-   3) Overall Thickness (positive rib+backweb+negative rib)—overall    thickness of the separator preferably between about 0.200 to 4.0 mm.-   4) Mass Reduction—preferably greater than 5%, more preferably    greater than 10%. The transverse ribs increase the transverse    rigidity of the separator and allow for the backweb or substrate    thickness to be decreased. Mass can be removed from both the backweb    and positive ribs while maintaining and increasing the transverse    rigidity. Also, the transverse negative ribs contribute to overall    thickness of the separator. Therefore the height of the longitudinal    positive rib can be directly reduced by the height of the negative    cross rib.-   5) Type of Separator—the separator can be made of porous materials,    such as microporous or macroporous thermoplastic material,    preferably polyethylene, polypropylene, polyvinyl chloride, and the    mixtures thereof, as well as of rubber, polyolefin, phenolic,    crosslinked phenolic resin, cellulosic, glass, or combinations    thereof.

Additional or alternative benefits of the addition of negative crossribs include:

-   1) Electrical Resistance Reduction—Since the negative cross rib    profile design allows for mass removal while maintaining equivalent    or higher transverse bending stiffness, the observed electrical    resistance will preferably be lower.-   2) Minimize Tear Propagation—When the separator is extremely    oxidized, a crack or split will likely develop in the backweb and    extend parallel to the major longitudinal rib. The negative cross    rib will preferably arrest the propagation of such tears due to, for    example, the extra mass in the ribs.-   3) Side Alignment—In the assembly process, the enveloped plates are    aligned horizontally and vertically before the strap is cast to    connect the positive and negative electrodes respectively. For    vertical alignment, the positive ribs provide a means for the    separator and plate to slide when contacting each other. For typical    side alignment, the negative plate may slide when contacting the    flat backweb. The negative transverse ribs, will preferably offer    less surface and should aid in side alignment operation.

In accordance with at least one embodiment, the separator is made up ofan ultrahigh molecular weight polyethylene (UHMWPE) mixed with aprocessing oil and filler of precipitated silica and/or reactivemineral. In accordance with at least one particular embodiment, thenegative cross ribs preferably have a 2 to 6 mil radius and a 10 to 50mil rib spacing.

In accordance with at least selected embodiments, the battery separatorincludes a porous membrane having a backweb and at least two rows ofpositive ribs on the positive side of the backweb, and a plurality ofnegative cross ribs or transverse ribs on the negative side of thebackweb. The positive ribs may be straight or wavy, may have a solidportion, and may have a truncated pyramidal shape. The membrane may beselected from the group of polyolefin, rubber, polyvinyl chloride,phenolic, cellulosic, or combinations thereof, and the membrane ispreferably a polyolefin material forming a battery separator for astorage battery.

A battery separator is used to separate the battery's positive andnegative electrodes, and is typically microporous so that ions may passthere through to the positive and negative electrodes. In lead/acidstorage batteries, either automotive or industrial batteries, thebattery separator is typically a microporous polyethylene separatorhaving a back web and a plurality of positive ribs standing on the backweb. The separators for automotive batteries are typically made incontinuous lengths and rolled, subsequently folded, and sealed along itsedges to form pouches that receive the electrodes for the batteries. Theseparators for industrial (traction) batteries are typically cut to asize about the same as an electrode plate (piece separator).

In one embodiment of the present method of making a lead/acid batteryseparator from a sheet of plastic material, the sheet is calender moldedto form cross or negative side transverse ribs or projections, andpreferably is calender molded to simultaneously form both positivelongitudinal ribs and negative cross or transverse ribs on oppositesides of the sheet.

With reference to FIG. 3, an exemplary lead/acid battery separator 40has a ribbed positive face 42 (i.e., with the primary ribs 46) and asmooth back face 44 (i.e., without ribs). The negative electrode (plate)is placed adjacent to the back face, and the positive electrode (plate)rests on the ribs 46 of the ribbed face 42. Once a battery issufficiently charged and current is continually applied (i.e.,overcharging), hydrogen is generated at the negative plate, and oxygenis generated at the positive plate. As hydrogen is formed at thenegative plate, it may push the separator away from the negative platethereby forming a gas pocket which may prevent the escape of gas. Atleast selected embodiments of the present invention may address thisissue and provide an improved battery separator. See for example, FIGS.6 to 8 of the drawings showing three selected separator embodiments. InFIG. 6, an exemplary separator 60 has a backweb 62, positive major ribs64 and minor negative cross ribs 66. The negative cross ribs extendacross the back or negative surface. In FIG. 7, an exemplary separator70 has a backweb 72, positive major ribs 74 and minor negative crossribs 76. The negative cross ribs extend across the back or negativesurface and are interrupted by shallow fissures or recesses 78 behindeach positive rib 74. These fissures 78 form channels which may providefor the escape of hydrogen gas, allow for extraction of plasticizer orlubricant from the positive ribs, and/or the like. In FIG. 8, anexemplary separator 80 has a backweb 82, positive major ribs 84 andminor negative cross ribs 86. The negative cross ribs extend across theback or negative surface and are interrupted by fissures or recesses 88behind each positive rib 84. These fissures 88 form channels which mayextend up into the positive rib, may provide for the escape of hydrogengas, may allow for extraction of plasticizer or lubricant from thepositive ribs, and/or the like. A separator having such channels thatallow any hydrogen gas to escape, may be preferred.

In at least one embodiment, the separator is made of a microporous,thermoplastic material which is provided with longitudinal positive ribsand transverse negative ribs with the height of at least a majority ofthe longitudinal ribs being greater than that of the transverse ribs,and the longitudinal and transverse ribs being solid ribs which areformed integrally from the plastic, characterized in that the transverseribs extend across substantially the entire back width of the separator.The separator sheet thickness may be approximately 0.10 to 0.50 mm, theheight of the longitudinal ribs may be 0.3 to 2.0 mm and the height ofthe transverse ribs may be 0.1 to 0.7 mm, the longitudinal rigidity with100 mm width may be approximately 5 mJ and the transverse rigidity maybe approximately 2.5 mJ, and the total thickness of the separator may beless than 2.5 mm.

With reference to FIG. 9 of the drawings, the separators according tothe present invention can be manufactured in a similar fashion asconventional polyethylene separators with the addition or substitutionof reactive mineral fillers, a negative roll having grooves to form thenegative cross ribs, a positive roll having no grooves or grooves ofless depth, and/or the like. With this preferred method, the plasticmaterial 90 containing filler is extruded through a slot die 92 to forma film 94 and then run through two calender rolls (positive roll 96,negative roll 98) by means of which both the positive longitudinal ribs100 and the negative transverse ribs are produced and the separatorsheet is reduced to the desired thickness. With reference again to FIG.9, positive roll 96 has shallow circumferential or annular grooves 102which form positive longitudinal ribs 100, and lands or smooth areas orstripes that form smooth areas on the separator for sealing the edges ofthe pockets. The negative roll 98 has shallow axial grooves which formthe cross ribs. Also, the negative roll 98 may have spaced sets ofshallow axial grooves with smooth lands or areas (for example, forwelding zones) there between.

The separators according to the present invention with negative crossribs preferably have a better machine workability than those withoutsuch transverse ribs, a better guidance of the separator tracks as aresult of increased transverse rigidity, and the processability forplacing the electrode plates in pockets should be improved because ofthe increased transverse rigidity. In addition, production of separatorswith a considerably reduced sheet thickness and consequently with areduced electrical resistance should be possible which is ofsignificance particularly in relation to efforts to constantly increasebattery output with a constant battery volume. The separators accordingto the invention should be able to be processed to form pockets withoutdifficulty on conventional machines. The additional transverse negativeribs should not cause problems either with the welding of the pockets bythe use of heat or ultrasonic means or with the mechanical process forproducing pockets.

In at least one particular embodiment, the separator made of elasticplastic and suitable for use in a lead acid storage battery, includessheet material with an inner region and two peripheral regions andhaving positive ribs running in the longitudinal direction with thelongitudinal ribs in the inner region being more widely spaced thanthose in the peripheral region, and having negative ribs running in thetransverse direction.

Referring to FIG. 2, another exemplary separator 30 is illustrated.Separator 30 has a negative electrode side 32 and a positive electrodeside 34 (the part folded over). The positive electrode side 34 includesa plurality of longitudinally extending major ribs 36. The negativeelectrode side 32 includes a plurality of longitudinally extending minorribs 38. One difference between major ribs 36 and minor ribs 38 is theirheight, major ribs 36 being greater in height than minor ribs 38.Another difference is the spacing between the ribs, major ribs 36 beingmore spaced apart than minor ribs 38.

Referring again to FIG. 3, the separator 40 has a positive electrodeside 42 and a negative electrode side 44. The positive electrode side 42includes a plurality of longitudinally extending ribs 46. The negativeelectrode side 44 (the part folded over) has no ribs.

A new or improved lead acid battery may preferably include: a housingcontaining a positive electrode spaced apart from a negative electrodewith a porous separator located between the positive electrode and thenegative electrode and an electrolyte in ionic communication between thepositive electrode and the negative electrode, and at least one of thehousing, separator, positive electrode, negative electrode, andelectrolyte include at least one natural or synthetic hydroxyapatitemineral.

A new or improved lead acid battery may preferably include: a housingcontaining a positive electrode spaced apart from a negative electrodewith a porous separator located between the positive electrode and thenegative electrode and an electrolyte in ionic communication between thepositive electrode and the negative electrode, and at least two of thehousing, separator, positive electrode, negative electrode, andelectrolyte include at least one natural or synthetic hydroxyapatitemineral.

A new or improved lead acid battery may preferably include: a housingcontaining a positive electrode spaced apart from a negative electrodewith a porous separator located between the positive electrode and thenegative electrode and an electrolyte in ionic communication between thepositive electrode and the negative electrode, and at least three of thehousing, separator, positive electrode, negative electrode, andelectrolyte include at least one natural or synthetic hydroxyapatitemineral.

A new or improved lead acid battery may preferably include: a housingcontaining a positive electrode spaced apart from a negative electrodewith a porous separator located between the positive electrode and thenegative electrode and an electrolyte in ionic communication between thepositive electrode and the negative electrode, and at least four of thehousing, separator, positive electrode, negative electrode, andelectrolyte include at least one natural or synthetic hydroxyapatitemineral.

A new or improved lead acid battery may preferably include: a housingcontaining a positive electrode spaced apart from a negative electrodewith a porous separator located between the positive electrode and thenegative electrode and an electrolyte in ionic communication between thepositive electrode and the negative electrode, and each of housing,separator, positive electrode, negative electrode, and electrolyteinclude at least one natural or synthetic hydroxyapatite mineral.

The new or improved separators of the present invention may find use asLead-Acid Battery Separators, separators for use in starting,deep-cycling and stand-by power battery applications, or in Flooded, Geland AGM battery types used in applications such as: starting,stationary, motive power and deep-cycle lead-acid battery applications,as well as for flooded and specialty lead-acid battery applications,and/or for premium lead-acid gel batteries. Further, such separators maybe used in other batteries, accumulators, capacitors, and/or the like.

In accordance with at least certain embodiments, it is preferred that atleast one source of hydroxyapatite mineral (such as ground fish meal) beadded to substitute for a portion of the silica filler in a silicafilled separator at substitution levels of about 1% to 50% of thesilica, more preferably about 5% to 30%, and most preferably at about10% to 20%.

In accordance with at least other certain embodiments, it is preferredthat at least one source of hydroxyapatite (such as ground fish meal) beadded as the filler in a filled separator at filler levels of about 1%to 75% filler, more preferably about 5% to 50%, and most preferably atabout 10% to 30%.

In accordance with at least still other certain embodiments, it ispreferred that at least one source of hydroxyapatite (such as groundfish meal) be added as filler in a battery separator at levels of about1% to 75% weight percent of the separator, more preferably about 2% to35%, and most preferably at about 5% to 20%.

In accordance with at least selected embodiments of the presentinvention, a believed novel concept of utilizing PIMS minerals as afiller component within a microporous lead-acid battery separator isprovided. In accordance with one particular embodiment or example, thePIMS mineral (preferably fish meal, a bio-mineral) is provided as atleast a partial substitution for the silica filler component in a silicafilled lead acid battery separator (preferably a polyethylene/silicaseparator formulation).

In accordance with at least certain embodiments of the presentinvention, a novel concept of utilizing one or more natural or syntheticPIMS minerals as a filler component within a microporous lead-acidbattery separator is provided. In accordance with more particularembodiments or examples, a PIMS mineral (preferably fish meal, abio-mineral) is provided as at least a partial substitution for thesilica filler component in a silica filled lead acid battery separator(preferably a polyethylene/silica separator formulation). In accordancewith at least selected embodiments, the present invention is directed tonew or improved batteries, separators, components, and/or compositionshaving heavy metal removal capabilities and/or methods of manufactureand/or methods of use thereof.

The present invention may be embodied in other forms without departingfrom the spirit and the essential attributes thereof, and, accordingly,reference should be made to the appended claims, rather than to theforegoing specification, as indicating the scope of the invention.

1. A battery separator having one or more PIMS minerals as a fillercomponent.
 2. The battery separator of claim 1, wherein the PIMSminerals are selected from one of fish bone or fish meal.
 3. The batteryseparator of claim 1, wherein the separator is a porous polyethylene andsilica filled battery separator having the one or more PIMS mineralssubstituted for at least a portion of the silica filler therein.
 4. In abattery, the improvement comprising the battery separator of claim
 1. 5.In a method of producing a silica filled battery separator, theimprovement comprising: substituting at least one PIMS mineral for atleast a portion of the silica filler.
 6. In a method of using a silicafilled battery separator in a lead acid battery including electrolyte,the improvement comprising: using the battery separator produced by themethod of claim 5 to bind at least a portion of the lead in theelectrolyte.
 7. A lead acid battery, comprising: a housing containing apositive electrode spaced apart from a negative electrode with a porousseparator located between the positive electrode and the negativeelectrode and an electrolyte in ionic communication between the positiveelectrode and the negative electrode, and wherein at least one of thehousing, separator, positive electrode, negative electrode, andelectrolyte include at least one natural or synthetic hydroxyapatitemineral.
 8. The battery of claim 7, wherein at least two of the housing,separator, positive electrode, negative electrode, and electrolyteinclude at least one natural or synthetic hydroxyapatite mineral.
 9. Thebattery of claim 7, wherein at least three of the housing, separator,positive electrode, negative electrode, and electrolyte include at leastone natural or synthetic hydroxyapatite mineral.
 10. The battery ofclaim 7, wherein at least four of the housing, separator, positiveelectrode, negative electrode, and electrolyte include at least onenatural or synthetic hydroxyapatite mineral.
 11. In a lead acid battery,the improvement comprising at least one of: a separator, component, orcomposition having heavy metal removal capabilities utilizing at leastone PIMS mineral; a battery casing, battery part, porous bag, laminate,non-woven, mat, paper, coating, surface, in-mold, filler, electrode,electrode formulation, electrolyte, polymer composition, or resincomposition having heavy metal removal capabilities utilizing at leastone PIMS mineral; a polymer or resin composition having heavy metalremoval capabilities utilizing at least one PIMS mineral as at least onefiller component therein; a silica filled microporous lead-acid batteryseparator having at least one PIMS mineral provided as at least apartial substitution for the silica filler therein; a silica filledmicroporous polyethylene lead-acid battery separator having ground fishmeal provided as at least a partial substitution for the silica fillertherein; or combinations thereof.
 12. A composition of matter havingheavy metal removal capabilities, comprising: a porous material and atleast one PIMS mineral.
 13. The composition of claim 12, wherein the atleast one PIMS mineral is at least one natural or synthetichydroxyapatite mineral.
 14. The composition of claim 13, wherein theporous material is a microporous polymer membrane.